JP6233384B2 - Coil end joining method for stator segment coil - Google Patents

Description

  The present invention relates to a method for joining coil ends of segment coils used in a stator.

  When manufacturing the stator of a motor, the segment coil which forms a coil by joining is used. Patent Document 1 describes a method of joining end portions of segment coils. This segment coil has a tapered tip, and is assembled in order from the radially inner side to the outer side of the stator core, and a pair of radially adjacent segment coils are opposite to each other in the circumferential direction of the stator core. Have been defeated. Thereby, the height of the coil end is shortened. And a conductive adhesive is apply | coated to the joining object part of the front-end | tip of a pair of segment coil used as joining object. Thereafter, a plurality of wedge-shaped plate-like bodies are inserted into the gaps at the tips of the pair of segment coils along the radial direction of the stator core, and the joining target portions are fixed at predetermined positions along the radial direction. Thereafter, the state in which the plate-like body is pressed with a predetermined pressure is maintained for a predetermined time to cure the conductive adhesive, thereby joining the end portions of the segment coils.

JP 2006-304507 A

The joining method of the edge part of the segment coil described in patent document 1 uses a conductive adhesive, and does not describe the joining method by welding. Further, according to this method, the position of the tip of the pair of segment coils can be positioned along the radial direction of the stator core, but the positioning along the axial direction and the circumferential direction of the stator core is not described. Therefore, when this method is used for welding the tips of the pair of segment coils, there is a problem that positioning along the axial direction and the circumferential direction of the stator core cannot be performed with high accuracy.
An object of this invention is to provide the coil end welding method which can perform positioning of the coil end of a segment coil correctly in manufacture of a stator core.

The present invention is a method for joining coil ends having a tapered portion in which a tip is tapered and a chamfered portion is formed on the stator core side in a segment coil for a stator,
Each segment coil formed in a predetermined shape in the stator core slot is assembled in turn from the inside in the radial direction of the stator core toward the outside,
In the stator core, the coil ends of a pair of the segment coils adjacent in the radial direction are tilted in opposite directions in the circumferential direction of the stator core,
A pair of first pressing jigs provided with a pair of claw portions fitted to a pair of tapered portions adjacent in the radial direction in a state where the coil end is folded down are arranged along the axial direction of the stator core. Pressing the pair of tapered portions close to the coil ends,
One claw portion of the pair of claw portions is fitted to the chamfered portion of one tapered portion of the pair of tapered portions, and the other claw portion is the chamfered portion of the other tapered portion of the pair of tapered portions. To fix the axial position of the pair of tapered portions,
The pair of tapered portions are sandwiched from the inside and outside in the radial direction by a pair of second pressing jigs to contact the pair of tapered portions and fix the radial position of the pair of tapered portions,
The contact portions of the pair of tapered portions are welded.

  According to the present invention, by such a configuration, the tapered portion of the coil end is pressed by the first pressing jig in the stator core, and the pair of claw portions of the first pressing jig are fitted to the pair of tapered portions. The position of the tapered portion along the axial direction of the stator core can be fixed at a predetermined position. The pair of tapered portions can be fixed at a predetermined position by sandwiching the pair of tapered portions along the radial direction of the stator core by the pair of second pressing jigs.

  The present invention further includes fitting one claw portion of the pair of claw portions to the chamfered portion of one tapered portion of the pair of tapered portions, and setting the other claw portion to the other tapered portion of the pair of tapered portions. The circumferential position of the pair of tapered portions is fixed by moving the pair of claw portions so as to approach each other along the circumferential direction while being fitted to the chamfered portion.

  The present invention clamps the pair of tapered portions along the circumferential direction of the stator core by moving the pair of claw portions so as to approach each other along the circumferential direction of the stator core, and extends along the circumferential direction of the stator core of the pair of tapered portions. The fixed position can be fixed at a predetermined position. In this state, the pair of tapered portions are fixed at predetermined positions in the axial direction by the pair of claw portions, and are fixed along the radial direction of the stator core by the pair of second pressing jigs. Yes. That is, according to the present invention, the tapered portion of the coil end can be fixed at a predetermined position with respect to the axial direction, the radial direction, and the circumferential direction of the stator core.

  The present invention further includes a fitting surface that is inclined in a direction along the circumferential direction and close to the stator core in the axial direction, so that the pair of claws are brought closer to each other along the circumferential direction. The chamfered portion of each of the pair of tapered portions is fitted to the fitting surface when the pair of tapered portions are moved, and the circumferential position of the pair of tapered portions is fixed.

  According to the present invention, since the fitting surface is formed on the claw portion of the first pressing jig, the tapered portion of the coil end is clawed when the first pressing jig is moved in the circumferential direction of the stator core. It can be reliably fitted to the part. Thereby, this invention can fix a taper part to the predetermined position reliably with respect to the axial direction simultaneously with the circumferential direction of a stator core.

According to the present invention, a through hole for welding the contact portion is formed in the first pressing jig, and the through hole corresponds to a position along the axial direction of the contact portion. In the position,
The contact portion is laser welded from the axial direction through the through hole.

  According to the present invention, a pair of tapered portions fixed at predetermined positions by the second pressing jig and the first pressing jig are arranged in the axial direction of the stator core through the through holes formed in the first pressing jig. The contact portions of the pair of tapered portions can be welded. By irradiating the laser through this through hole, the contact portion can be welded without affecting the portions other than the pair of tapered portions to be welded.

  According to the present invention, when the coil ends of the segment coils are joined in manufacturing the stator core, the coil ends of the segment coils can be accurately positioned.

It is the figure which showed the stator core which concerns on the manufacturing object of this invention. It is the figure which showed the joining object part of a segment coil. It is the figure which showed the joining object part of a segment coil. It is the figure which showed the front-end | tip part of the coil end of a segment coil. It is the figure which showed the modification of the front-end | tip part of the coil end of a segment coil. It is sectional drawing which showed the structure of the coil end joining apparatus which concerns on this invention. It is sectional drawing which showed the structure of the coil end joining apparatus from the other direction. It is the perspective view which showed the nail | claw part of the 1st pressing jig. It is the figure which showed the joining method of the coil end by a coil end joining apparatus. It is the figure which showed the positioning of the coil end by a 1st pressing jig. It is the figure which showed the positioning of the coil end by a 1st pressing jig. It is the figure which showed the error of the bending of a coil end. It is the figure which showed the positioning of the coil end by a 1st pressing jig. It is the figure which showed the clamp apparatus which is a modification of a coil end joining apparatus. It is sectional drawing which showed the structure of the clamp apparatus. It is the perspective view which showed the nail | claw part of the clamp apparatus.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of a coil end joining apparatus and joining method for a stator segment coil according to the present invention will be described with reference to the drawings.

  As shown in FIGS. 1 and 2, the motor stator 1 includes an annular stator core 2 and a plurality of segment coils 4 for forming a coil 3 inside the stator core 2. The stator core 2 is formed by superimposing thin annular iron plates. Inside the stator core 2, a plurality of segment coils 4 formed in a U shape are arranged along the circumferential direction of the stator core 2. The plurality of segment coils 4 are stacked in order from the inside toward the outside along the radial direction of the stator core 2. A coil 3 is formed by the plurality of segment coils 4 assembled in this manner.

  As shown in FIG. 3, the pair of coil ends 5 of the pair of segment coils 4 adjacent to each other in the radial direction of the stator core 2 are tilted in opposite directions in the circumferential direction of the stator core 2. The tip end of the coil end 5 has a tapered portion 6 formed in a tapered shape. The tapered portion 6 is formed in a shape such that the coil end 5 is cut in parallel with the stator core 2. Thereby, the height along the axial direction of the stator core 2 of the coil end 5 is shortened. The tips of a pair of adjacent coil ends 5 are welded to each other and are electrically connected.

  As shown in FIG. 4, a chamfered portion 7 is formed at the tip of the tapered portion 6 so that the tip jumps up in the axial direction of the stator core 2. The chamfered portion 7 is formed so that the tip angle of the tapered portion 6 becomes dull. The angle θ of the tip of the tapered portion 6 is less than 90 °. As shown in FIG. 5, the chamfered portion 7 may be formed in an R shape so as to protrude toward the stator core 2. The tapered portion 6 is formed as follows, for example. A bent portion is formed by bending a part of the strip-shaped conducting wire extended linearly so that the axis of the conducting wire is displaced in parallel to the longitudinal direction of the section of the strip. For example, the bent portion forms a conductive wire in a mold. Thereafter, the bent portion is pressed from both side surfaces in the short direction of the cross section of the belt. Then, the taper part 6 which has the chamfering part 7 is formed by cut | disconnecting diagonally with respect to the axis line of conducting wire from the longitudinal direction of the cross section of the band of this bending part.

  The tip ends of a pair of adjacent tapered portions 6 are welded. In the circumferential direction of the stator core 2, the welded portions of the pair of tapered portions 6 (locations from which the insulating film has been removed) are arranged with a gap. By forming the tip of the tapered portion 6 in such a shape, the insulation distance of the welded portion adjacent in the circumferential direction of the stator core 2 can be increased. By increasing the insulation distance, the eddy current loss of the segment coil 4 can be reduced. Hereinafter, the coil end joining apparatus 50 and welding method used for a pair of adjacent coil ends 5 will be described.

  As shown in FIGS. 6 to 8, the coil end joining device 50 includes a pair of first pressing jigs 10 and 10 ′ for positioning the stator core 2 in the axial direction and the circumferential direction of the coil end 5, and The coil end 5 has a pair of second pressing jigs 20 and 20 ′ for positioning the stator core 2 in the radial direction.

  The coil end 5 ′ is adjacent to the coil end 5 in the radial direction (Y direction) of the stator core 2 so that the tip is in the opposite direction. The tapered portion 6 of the coil end 5 is fitted with a first pressing jig 10 for positioning the stator core 2 along the axial direction (Z direction) and the circumferential direction (X direction) of the tapered portion 6. Yes. A flat portion 11 that is flat along the X direction for pressing the tapered portion 6 is formed at the bottom of the first pressing jig 10.

  The flat portion 11 has a claw portion 12 formed so as to protrude downward (−Z direction). The claw portion 12 has a fitting surface 14 that is inclined in the moving direction (−X direction). The fitting surface 14 is inclined in a direction close to the stator core 2 in the axial direction (Z direction) along the circumferential direction (X direction). The claw portion 12 is formed so as to enter the space S formed by the chamfered portion 7 and the coil end 5 adjacent in the X direction so as not to interfere with the coil end 5 adjacent in the X direction. The tapered portion 6 is fitted to the first pressing jig 10 by the flat portion 11 and the claw portion 12.

  A first pressing jig 10 ′ for pressing the coil end 5 ′ is adjacent to the first pressing jig 10 in the −Y direction. The coil end 5 ′ and the first pressing jig 10 ′ have the same configuration and shape as the coil end 5 and the first pressing jig 10, respectively, and are arranged rotationally symmetrical with respect to the Z axis. . Therefore, hereinafter, the coil end 5 ′ and the first pressing jig 10 ′ are the same as those described above. The first pressing jig 10 is formed with a through-hole 13 penetrating along the Z-axis direction. The through hole 13 is provided through the first pressing jig 10 at a position corresponding to the position along the Z-axis direction of the tapered portion 6. One through hole for welding the coil end 5 is formed by the through hole 13 and the through hole 13 '.

  As shown in FIG. 9, the first pressing jig 10 moves along the Z axis so as to approach the coil end 5 in the −Z direction, and stops at the reference position P while applying a force in the −Z direction. To do. At this time, the claw portion 12 enters the space S so as not to contact the chamfered portion 7. As a result, the upper end of the tapered portion 6 of the coil end 5 comes into contact with the flat portion 11, and the coil end 5 is given a force in the −Z direction by the first pressing jig 10. At this time, the upper end of the tapered portion 6 is disposed at the reference position P, and the position of the tapered portion 6 in the Z-axis direction is fixed.

  Similarly, the taper portion 6 ′ of the coil end 5 ′ is also fixed in the Z-axis direction by the first pressing jig 10 ′. That is, the pair of tapered portions 6 and 6 ′ are pressed in the axial direction of the stator core 2 by the pair of first pressing jigs 10 and 10 ′, and the pair of tapered portions 6 and 6 ′ are positioned in the axial direction of the stator core 2. Is fixed.

  Thereafter, the first pressing jig 10 moves in the −X direction, and the claw portion 12 comes into contact with the chamfered portion 7. Thereby, the taper part 6 fits into the 1st pressing jig 10, and the position of the X-axis direction of the taper part 6 is fixed. Similarly, the position of the tapered portion 6 'of the coil end 5' is fixed in the X-axis direction by the first pressing jig 10 '. That is, the pair of claw portions 12, 12 with the claw portion 12 fitted to the chamfered portion 7 of the tapered portion 6 and the claw portion 12 'fitted to the chamfered portion 7' of the tapered portion 6 '. 'Is moved so as to approach each other along the circumferential direction, and the circumferential position of the pair of tapered portions 6, 6 ′ is fixed.

  At this time, when the pair of claw portions 12 and 12 'are moved so as to approach each other along the circumferential direction, the chamfered portions 7 and 7' of the pair of tapered portions 6 and 6 ' The surfaces 14 and 14 'are fitted, and the circumferential positions of the pair of tapered portions 6 and 6' are fixed. Thereby, a pair of taper part 6,6 'is pinched | interposed and fitted from the circumferential direction of the stator core 2 by a pair of 1st pressing jigs 10,10', and the stator core 2 of a pair of taper part 6,6 ' The position in the circumferential direction is fixed.

  As shown in FIGS. 10 to 13, the position of the segment coil 4 has various variations. When the bending angle of the segment coil 4 is small, the coil end 5 protrudes upward (Z-axis direction) from the reference position P (see FIG. 10). In this case, the first pressing jig 10 descends along the Z axis and presses the tapered portion 6 downward, so that the tapered portion 6 is disposed at the reference position P. On the other hand, when the bending angle of the segment coil 4 is large, the coil end 5 is positioned downward (−Z direction) from the reference position P (see FIG. 11). In this case, the first pressing jig 10 moves along the X axis, and the tapered portion 6 is pulled upward by the claw portion 12. That is, the chamfered portion 7 of the tapered portion 6 is slid up on the fitting surface 14 of the claw portion 12 to fit the tapered portion 6 into the claw portion 12. As a result, the tapered portion 6 is disposed at the reference position P.

  If the bending R of the segment coil 4 is too large (see FIG. 12), the position of the coil end 5 is shifted in the X-axis direction. In this case, the first pressing jig 10 moves along the X axis, and the tapered portion 6 is moved in the −X direction by the claw portion 12, whereby the axial direction of the segment coil 4 is caused by the claw portion 12 and the flat portion 11. A force to be compressed is applied, the bend R is reduced, and the tapered portion 6 is disposed at a normal position (see FIG. 13).

  Next, positioning of the coil end 5 in the radial direction of the stator core 2 will be described. The pair of coil ends 5, 5 ′ are sandwiched by the pair of second pressing jigs 20, 20 ′ along the Y-axis direction (see FIG. 7). Protrusions 22 and 22 ′ that sandwich the pair of tapered portions 6 and 6 ′ from both side surfaces are provided at the tip portions 21 and 21 ′ of the pair of second pressing jigs 20 and 20 ′. The protrusions 22 and 22 ′ are formed so as to protrude in the −Z direction so as to enter the spaces Q and Q ′ between a plurality of adjacent tapered portions 6 and 6 ′ in the radial direction of the stator core 2. In other words, the pair of coil ends 5 and 5 ′ are sandwiched by the pair of second pressing jigs 20 and 20 ′ from the inner side and the outer side in the radial direction of the stator core 2. Thereby, the movement of the pair of coil ends 5, 5 'in the Y-axis direction is restricted. And a pair of taper part 6 fixes the position of the radial direction of stator core 2 to a regular position.

  The pair of tapered portions 6, 6 ′ is formed by the pair of first pressing jigs 10, 10 ′ and the pair of second pressing jigs 20, 20 ′. And fixed in a triaxial direction with respect to the direction and arranged at a normal position. At this time, the pair of tapered portions 6 and 6 ′ are in contact with each other and a contact portion B is formed. The contact portion B is confirmed from above the Z axis through the through holes 13 and 13 '. Thereafter, the contact portion B is welded by the laser 31 through the through holes 13 and 13 ′ by the laser welding machine 30 from above in the Z-axis direction. When the laser is irradiated from the through holes 13 and 13 ′, the contact portion B can be welded without affecting the portions other than the contact portion B to be welded.

  As described above, according to the welding method of the coil end 5 of the segment coil 4, when the coil end 5 has the tapered portion 6 formed in the tapered shape, the pair of tapered portions 6 and 6 ′ are positioned at the normal positions. Can be accurately positioned. The pair of tapered portions 6 and 6 'can be laser-welded by the through holes 13 and 13' provided in the pair of first pressing jigs 10 and 10 '. The through holes 13 and 13 ′ do not affect other places that are not welded. And according to the welding method of the coil end 5, the full length of the segment coil 4 can be shortened and the motor manufactured can be reduced in size. Moreover, the manufacturing cost of a motor can be reduced by shortening the full length of the segment coil 4. FIG.

  Note that the present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit of the present invention.

  As shown in FIG. 14, a plurality of pairs of first pressing jigs 10, 10 ′ and a pair of second pressing jigs 20, 20 ′ are arranged so as to extend in the circumferential direction of the stator core 2. You may provide the clamp apparatus 40 formed in this way. In the following description, the same components as those described above are denoted by the same names and symbols, the same components are denoted by the same names, and duplicate descriptions are omitted.

  The clamp device 40 includes an annular inner peripheral side clamp 41, an annular outer peripheral side clamp 42 disposed on the outer periphery of the inner peripheral side clamp 41, and a plurality of radially disposed outer peripheral sides of the outer peripheral side clamp 42. A second holding jig 43. A plurality of through holes 41a and 42a are formed in the inner peripheral side clamp 41 and the outer peripheral side clamp 42, and a through hole H is formed by the pair of through holes 41a and 42a. The inner peripheral side clamp 41 and the outer peripheral side clamp 42 are relatively concentrically rotatable.

  As shown in FIG. 15, the second pressing jig 43 is disposed on the side surface of the outer peripheral side clamp 42 so as to be slidable in the Y-axis direction. A protrusion 41 b is provided on the lower surface of the inner periphery side clamp 41 so as to face the second pressing jig 43. The pair of tapered portions 6 and 6 ′ are clamped along the Y-axis direction by the second pressing jig 43 and the protruding portion 41 b.

  As shown in FIG. 16, the pair of tapered portions 6, 6 ′ includes a claw portion 41 c formed on the lower surface of the inner peripheral side clamp 41 and a claw portion 42 c formed on the bottom surface of the outer peripheral side clamp 42. 2 in the circumferential direction. A number of pairs of tapered portions 6, 6 ′ extending in the circumferential direction of the stator core 2 are positioned in the circumferential direction of the stator core 2 by relative rotation of the inner peripheral side clamp 41 and the outer peripheral side clamp 42. The multiple pairs of tapered portions 6 and 6 ′ are positioned in the axial direction of the stator core 2 by the inner peripheral side clamp 41 and the outer peripheral side clamp 42. Thereafter, the contact portions B of the multiple pairs of tapered portions 6, 6 ′ are laser welded through the through holes H.

  The other multiple pairs of taper portions 6 and 6 ′ that further extend in the circumferential direction of the stator core 2 are positioned and clamped by a clamp device 40 having different outer diameters.

DESCRIPTION OF SYMBOLS 1 ... Stator 2 ... Stator core 3 ... Coil 4 ... Segment coil 5 ... Coil end 6 ... Tapered part 7 ... Chamfering part 10 ... 1st holding jig 11 ... Flat part 12 ... Claw part 13 ... Through-hole 14 ... Fitting surface DESCRIPTION OF SYMBOLS 20 ... 2nd holding jig 30 ... Laser welding machine 31 ... Laser 40 ... Clamping device 41 ... Inner circumference side clamp 41a ... Through-hole 41b ... Projection part 41c ... Claw part 42 ... Outer circumference side clamp 42c ... Claw part 43 ... First 2 holding jigs 50 ... Coil end joining device

Claims (4)

In a segment coil for a stator, a coil end joining method having a tapered portion in which a tip is tapered and a chamfered portion is formed on the stator core side,
Each segment coil formed in a predetermined shape in the stator core slot is assembled in turn from the inside in the radial direction of the stator core toward the outside,
In the stator core, the coil ends of a pair of the segment coils adjacent in the radial direction are tilted in opposite directions in the circumferential direction of the stator core,
A pair of first pressing jigs provided with a pair of claw portions fitted to a pair of tapered portions adjacent in the radial direction in a state where the coil end is folded down are arranged along the axial direction of the stator core. Pressing the pair of tapered portions close to the coil ends,
One claw portion of the pair of claw portions is fitted to the chamfered portion of one tapered portion of the pair of tapered portions, and the other claw portion is the chamfered portion of the other tapered portion of the pair of tapered portions. To fix the axial position of the pair of tapered portions,
The pair of tapered portions are sandwiched from the inside and outside in the radial direction by a pair of second pressing jigs to contact the pair of tapered portions and fix the radial position of the pair of tapered portions,
Welding the contact portions of the pair of tapered portions;
Coil end joining method. One claw portion of the pair of claw portions is fitted to the chamfered portion of one tapered portion of the pair of tapered portions, and the other claw portion is the chamfered portion of the other tapered portion of the pair of tapered portions. Fixing the circumferential position of the pair of tapered portions by moving the pair of claw portions closer to each other along the circumferential direction in a state fitted to
The joining method according to claim 1. The claw portion has a fitting surface that is inclined in a direction close to the stator core in the axial direction along the circumferential direction, so that the pair of claw portions can be brought closer to each other along the circumferential direction. The chamfered portion of each of the pair of tapered portions is fitted to the fitting surface when moved to the position, and the circumferential position of the pair of tapered portions is fixed.
The joining method according to claim 1 or 2. A through hole for welding the contact portion is formed in the pair of first pressing jigs, and the through hole is located at a position corresponding to a position along the axial direction of the contact portion. Provided along the axial direction,
Laser welding the contact through the through hole;
The joining method according to any one of claims 1 to 3.

Images